PHP PH51W Manual de lista de piezas
®
PH51W COOLANT HEATER
Technical Description
Installation Instructions
Operating Instructions
Troubleshooting and Parts
3
Table of Contents
Introduction 4
Heater Warnings 5
Specications 6
Heater Components and Operating Concept 7
Heater Kit List 8
Heater Mounting 10
Exhaust & Combustion Air Intake Connections 11
Heater Plumbing 13
Fuel System 15
Electrical Connections 18
Operating Switch 20
Heater Operation 29
Maintenance, Troubleshooting & Parts 31
Heater Components 33
4
Introduction
Thank you for purchasing our PH51W heater kit.
The PH51W heater is designed to preheat your engine by using on-board diesel fuel and
battery systems. Operation is simple and the heater provides a safe and reliable alternative to
cold engine starting or need for electrical plug ins.
Please take a moment to familiarize yourself with this manual, safety warnings and heater
requirements before installing or operating your heater.
5
Heater Warnings
Special Notes
Note: Highlight areas requiring special attention or clarication.
Warning
Caution
Indicates that personal injury or damage to equipment may occur unless specic guidelines
are followed.
Indicates that serious or fatal injury may result if specic guidelines are not followed.
Caution - Operational Considerations
• The installation of this kit requires trained decision-
making concerning locating and integrating components,
tying components together, rerouting, or relocating OEM
components, etc.
• It is impossible to describe all of the safety and operational
considerations in the installation instructions. Therefore,
the technician must exercise professional judgment to
achieve a safe and quality installation.
• Read and understand this manual before attempting to
install the heater.
• Failure to follow all these instructions could cause serious
or fatal injury.
• Ensure a proper mixture of water and antifreeze to prevent
coolant from Freezing.
• Ensure that the coolant ow can never be blocked while
heater is in operation.
• Blocking coolant ow can result in extreme pressure,
bursting hoses and release of scalding coolant.
This heater is not designed for use with straight bio-diesel
(Blends of bio-diesel up to 10% are acceptable)
Operating outside of these conditions may plug the heater
with soot and result in combustion failure.
This heater is not designed to operate continuously at
altitudes above 1500 meters (4920’).
Operating in these conditions may plug the heater with soot
and result in combustion failure.
• Heater must be turned o while re-fueling.
• Do not install heater in enclosed areas where combustible
fumes may be present.
• Exhaust pipe must maintain a minimum a distance of
50mm (2”) from any ammable or heat sensitive material.
• Ensure there are no leaks in the fuel system.
• Ensure that exhaust fumes cannot enter passenger
compartments.
Warning - Installation Hazards
Warning - Burn Hazards
Bio-Diesel
High Altitudes
Warning - Explosion Hazards
Warning - Fire Hazards
Warning - Asphyxiation Hazards
6
Specications
Principal Dimensions
1
Technical data and specications
Heat ow control
♦ Please note:
♦ Heater Dimensions
Water outlet
Water inlet
Fuel
supply
line
Combustion air Exhaust
Performance Specifications
Heating Medium Water / Ethylene Glycol Mixture
Fuel Diesel
Heating Output High – 4.2 KW (14,400 BTU)
Low – 2.2 KW (7,500 BTU)
Fuel Consumption High – 0.51 L/hr (0.13US Gal/hr)
Low – 0.25 L/hr (0.06 US Gal/hr)
Rated Voltage 12 VDC or 24 VDC
Power Consumption
Watts
High – 53W
Low – 27 W
Startup – 120 W
Operating Voltage Range:
Minimum Voltage
10.2 V or 21V
Under-voltage protection will shutdown the units
when the voltage drops to this value
Operating Voltage Range:
Maximum Voltage
16 V or 32V
Over-voltage protection will shutdown the units when
the voltage reaches this value
Allowable Operating Pressure 1 bar (15 PSI)
Water Capacity (Heater) 0.175 L (0.046 US Gal)
Water Through Capacity 850-1000 L/h (225-265 US Gal/h)
At 10 Kpa Operational Pressure
Minimum Water Through-put 240 L/h (63.50 US Gal/h)
Allowable Ambient Temperature -40°C to 80°C
-40°F to 176°F
Dry Weight 3.1 kg (6.8 lbs)
Above Specifications (± 10%)
7
Main Components and Operating Concept
Main parts of PH51W water heaters
♦
1
2
3
4
1. Heat Exchanger 4. Glow Pin
2. Integrated Coolant Pump Assembly 5. Fuel Metering Pump
3. Combustion Air Blower
Basic Operation of Heater
• Fuel is delivered to the heater via the heater’s fuel pump.
• Combustion air is delivered to the heater via the heaters 12v combustion air blower.
• Fuel is atomized and the fuel / air mixture is ignited using a glow pin.
• The ame is contained in a ame tube and exhaust gases expelled.
• The heater’s coolant pump takes cold coolant from the engine, circulates it through the heater’s water
jacket, then it pumps hot coolant back to the engine.
5
8
Heater Kit List
Part Number QTY Description
P51W-T801 1 Heater
P65D-X302 1 Standard Operating Switch
P65D-X301 Operating Switch-7 day Timer (option)
P51W-X703 1 Heater Mounting Bracket
P65W-X303 1 Wiring Harness
5M (16’) Power Harness, 20A Fuse
2.5M (9’) Fuel Pump Harness
5M (16’) Switch Harness, 5A Fuse
2.5M (8’) Remote Sensor Harness
U65D-X508 1 Flexible Stainless-Steel Exhaust,
1M x 24mm with End Cap
U51W-X501 1 Combustion Air Intake Tube,
1M x 20mm
U65D-X405 1 Fuel Pickup Tube & Fuel Tube Hardware Kit
NPN 2 In-Line Plumbing Union, 20mm (3/4”)
NPN 2 Plumbing “Y” 20mm (3/4”)
P65D-T401 1 Fuel Metering Pump
U65D-X404
U65D-X407
U65D-X414
1
1
Fuel System Hardware
Fuel Pump Holder
Black Rubber Fuel Line, 4.5mm ID x 0.5M
U65D-X409
U65D-X403
U65D-X401
U65D-X402
U65D-X705
6
1
12
1
10
4.5mm ID x 50mm Rubber Fuel Line Connectors
Clear Nylon Fuel Line, 8M (26’) 2.0 mm ID
Small Fuel Line Clamps, 9-11 mm
Fuel Filter
Cable Ties, Medium Grade
9
Heater Kit List
P51W-X710
U65D-X706
U65D-X707
U65D-X502
U65D-X701
NPN
U65D-X521
NPN
NPN
NPN
NPN
NPN
U65D-X702
2
1
1
2
3
1
10
10
10
10
1
10
Installation Hardware
“L” Brackets
“Z” Mounting Bracket
26 – 28 mm Exhaust Clamp
28 mm “P”Routing Clamp
Tek Mounting Screws M6 x 25 mm
11-25 mm hose clamp
M6-1 x 25 Hex Head Screw
M6-1 Hex Nuts
6mm Wave washers
6mm Flat Washer
Hex Socket Cap Screw, M6 x 110
Water Hose Clamps 18mm-32mm, 12mm Wide
1
1
1
1
1
Literature Bag
Packing List
5 amp Fuse (Extra)
20 amp Fuse (Extra)
Spare Fuel Filter (Internal)
North American Manual
10
Heater Mounting
Note:
Bleed screw must be upward
Mounting Considerations
• Protect from road spray
• Mount below engine coolant level to avoid air blockage.
• Keep coolant hoses short to maximize ow and minimize heat loss.
• Keep power wiring short to minimize voltage drop.
• Keep fuel lines short to ensure good combustion.
Suggested Locations
• Step box
• External storage compartments (Not inside cab)
• Inside frame rail
• Inside engine compartment
Do not mount the heater inside passenger compartments where poisonous exhaust fumes may be inhaled.
Guard the heater against excessive road spray to minimize corrosion and avoid ingestion of debris.
Mounting
Mount the heater using the mounting bracket provided with the installation kit.
Provide shielding as required to protect the heater from environmental conditions.
Orientate the heater within permissible mounting congurations shown in Figure M1.
Warning - Asphyxiation Hazards
Caution
coolant level in order to allow the air to escape and ll up the heater with water or coolant when the bleed screw is open.
♦ Tolerable swivel range
Note:
♦ Please note:
Engine cooling system and heater hose connection
♦ Hose Connection Diagram
Cut water hose from the engine to the heater core, hook up the hose from engine to the inlet tting of the
Bleed screw Bleed screw
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